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Abstract:

The invention relates to a method of producing a top layer (10)
constituting a layer (6) of a gliding device (1), which top layer (10)
comprises an external face (18) and an internal face (24) directed
towards a core (9) of the gliding device (1). The top layer (10) is
provided with at least one hole (20) extending between the external face
(18) and the internal face (24). Prior to making the hole (20) through
the top layer (10), an adhesive layer (23) is applied to it on the
internal face (24) facing away from the external face (18), at least in
the region where the hole (20) is to be made, and the hole (20) is made
jointly both through the top layer (10 ) and through the adhesive layer
(23).

Claims:

1. A method of producing a top layer constituting a layer of a gliding
device such as a ski or a snowboard, whereby the top layer comprises an
external face and an internal face which can be directed towards a core
of the gliding device and is provided with a plurality of holes extending
between the external face and the internal face, wherein prior to making
the plurality of holes in the top layer, an adhesive layer is applied to
it on the internal face facing away from the external face, at least in
the region where the plurality of holes are to be made, and the plurality
of holes are made both through the top layer and through the adhesive
layer jointly.

2. The method according to claim 1, wherein the at least one hole is made
by a punching process.

3. The method according to claim 1, wherein the adhesive layer is applied
to the full surface of the entire internal face before making the at
least one hole through the top layer and adhesive layer.

4. The method according to claim 1, further comprising applying heat to
activate the adhesive layer.

5. The method according to claim 1, further comprising applying pressure
to activate the adhesive layer.

6. The method according to claim 1, further comprising placing another
layer on the side of the top layer facing away from the external face and
on the adhesive layer, to which the top layer is bonded by means of the
adhesive layer.

7. The method according to claim 6, wherein the other layer is made from
a material of a different color from that of the top layer.

Description:

CROSS-REFERENCE TO RELATED APPLICATION

[0001] The present application is a divisional of U.S. patent application
Ser. No. 12/643,183, filed on Dec. 21, 2009, the disclosure of which is
incorporated herein by reference.

BACKGROUND OF THE INVENTION

[0002] The invention relates to a method of manufacturing a top layer for
a gliding device and a gliding device incorporating such a top layer.

[0003] Document DE 20 2004 019 895 U1 discloses a snow gliding board with
a gliding layer and an external face formed by a top decorative and
protective element. The decorative and protective element is decorated on
at least one of its faces and has one or more holes. An inner structure
forming a core is enclosed by at least one inner reinforcement
impregnated with resin, which is disposed underneath the top decorative
and protective element. A barrier film of light-permeable or transparent
polymer is also provided, at least in the region between the holes and
the resin-impregnated reinforcement, the dimensions of which are bigger
than the dimensions of the holes or the arrangement of holes. The barrier
film also has holes, which are penetrated by resin from the impregnated
reinforcement during the joining process, thereby producing a knoll
inside the hole, which imparts an aesthetic effect.

[0004] Document DE 200 18 778 U1 discloses a gliding board designed for
surfing on snow. In order to improve grip, cut-outs are provided in a
longitudinal edge region of the top protective layer, which are of the
same thickness as the protective layer. The cut-outs are made by cutting
into the protective layer before the elements forming the board are
placed in the casting mold. To this end, the protective layer may be
processed by machine or clinched. One advantage obtained as a result of
this technique is that one and the same casting mold can be used to
produce boards with a smooth top face or a top face incorporating
cut-outs. During the joining process, there is a risk that surplus
adhesive material may penetrate the cut-outs.

BRIEF SUMMARY OF THE INVENTION

[0005] The underlying objective of this invention is to propose a method
of producing a top layer with at least one hole extending through it for
a gliding device, whereby the top layer can be easily processed during
the operation of joining it to the gliding device.

[0006] This objective is achieved by the invention on the basis of the
approach defined by the characterizing features of claim 1. The advantage
obtained as a result of the characterizing features defined in claim 1
resides in the fact that the adhesive layer is applied to the top layer
on the internal face designed to produce a bond, at least in the region
where the hole will be produced, and the hole is not made until the
adhesive layer has been applied and set, and is formed jointly in a
single work process through both the top layer and the adhesive layer.
This results in a bonding region on the internal face designed for
producing a bond, which is limited exclusively to the surface portions
surrounding the hole which are coated with the adhesive. Also as a
result, no adhesive is left in the cross-section of the hole during the
joining process through to obtaining the finished gliding device and
there is therefore no risk of soft adhesive getting into the hole and
closing it up. This is particularly crucial if using pressure molds
because this avoids creating additional mess and means that there is no
need for subsequent cleaning processes. Production reliability is
improved as a result and susceptibility to disruptions as well as
maintenance work are significantly reduced. The hole or holes is or are
used to improve the grip of the gliding device, which needs to be
improved or increased in particular in the case of smooth surfaces, in
order to enhance comfort when it is being carried. However, this also
obviates the need for additional mutual orientation operations in
situations where the top layer and the adhesive layer incorporating
co-operating holes are made separately. As a result, a clean adhering
process is obtained in the region of the hole and the adhesive extends as
far as the circumference of the hole and terminates at it in order to
produce a better seal. The entire operation of processing such a top
layer during the production process is therefore improved because top
layers can be pre-coated with the adhesive layer and, depending on the
chosen pattern or disposition of holes, these can then be formed and made
jointly through the two materials.

[0007] An approach as defined by the characterizing features specified in
claim 2 is also of advantage because in spite of the large number of
holes produced, a perfect bonding operation is achieved by the adhesive
layer applied to the internal face. Furthermore, not only does this mean
that special gripping zones can be produced, it also offers an additional
visual design option. Increasing the number of holes also results in a
reduction in weight, especially in the case of thicker or higher density
top layers.

[0008] Another advantageous approach is defined in claim 3, whereby a cut
for producing the hole can be made more cheaply and above all more
cleanly. Additional advantages can be obtained on the basis of the
combination of materials chosen, depending on the chosen punching
direction, be it from the top layer through to the adhesive layer or vice
versa.

[0009] Another variant of the method defined in claim 4 is also of
advantage because subsequent coating processes can be dispensed with and
the top layer can be processed to obtain the completed gliding device
once the holes have been made, without the need for other finishing
operations.

[0010] Another approach based on the characterizing features defined in
claim 5 is of advantage because the adhesive layer can be applied to the
internal face of the top layer in advance, after which the bonding
process can proceed in a known manner.

[0011] Another advantageous approach is defined in claim 6, whereby
excessive thermal stress to the material of the top layer can be avoided.

[0012] Another advantageous approach is defined in claim 7, whereby the
bonding process can proceed without the need for additional adhesive
layers and an exclusive bond is produced only on those surfaces coated
with the adhesive, excluding the holes.

[0013] Another variant of the method defined in claim 8 offers advantages
because the holes disposed in the top layer in conjunction with the other
layer joined to it not only enable a stable bond to be obtained but also
offer the possibility of a visual design defining the overall appearance
of the gliding device.

[0014] Finally, the objective of the invention can be achieved on the
basis of the characterizing features defined in claim 9. The advantages
obtained as a result of the combination of features defined in this claim
reside in the fact that a gliding device can be produced which, in spite
of having an arrangement of holes in the top layer, can be easily and
reliably processed. This approach obviates the need for additional
coating processes and mutual orientation steps in the region of the top
layer and adhesive layer, which not only leads to a perfect bonding
result but also means that an attractive visual appearance can be
imparted to the entire gliding device, including in the region of the
hole or holes.

BRIEF DESCRIPTION OF THE DRAWING

[0015] To provide a clearer understanding of the invention, it will be
described in more detail with reference to the appended drawings.

[0016] These are highly schematic, simplified diagrams showing the
following:

[0017] FIG. 1 is a highly simplified plan view, out of proportion, of a
board-type gliding device, in particular a ski, with a
three-dimensionally structured top face and a schematically indicated
binding unit;

[0018] FIG. 2 is a highly simplified, schematic diagram showing the
gliding device illustrated in FIG. 1 in cross-section along line II-II
indicated in FIG. 1;

[0019] FIG. 3 is a highly simplified plan view, out of proportion,
illustrating a board-type gliding device, in particular a snowboard with
a three-dimensionally structured top face and a schematically indicated
binding unit;

[0020] FIG. 4 is a diagram illustrating a detail from the cross-sectional
diagram of FIG. 2 but on a larger scale.

DETAILED DESCRIPTION

[0021] Firstly, it should be pointed out that the same parts described in
the different embodiments are denoted by the same reference numbers and
the same component names and the disclosures made throughout the
description can be transposed in terms of meaning to same parts bearing
the same reference numbers or same component names. Furthermore, the
positions chosen for the purposes of the description, such as top,
bottom, side, etc., relate to the drawing specifically being described
and can be transposed in terms of meaning to a new position when another
position is being described. Individual features or combinations of
features from the different embodiments illustrated and described may be
construed as independent inventive solutions or solutions proposed by the
invention in their own right.

[0022] All the figures relating to ranges of values in the description
should be construed as meaning that they include any and all part-ranges,
in which case, for example, the range of 1 to 10 should be understood as
including all part-ranges starting from the lower limit of 1 to the upper
limit of 10, i.e. all part-ranges starting with a lower limit of 1 or
more and ending with an upper limit of 10 or less, e.g. 1 to 1.7, or 3.2
to 8.1 or 5.5 to 10.

[0023] FIGS. 1 to 4 illustrate two embodiments of board-type gliding
devices 1 for gliding on ice, snow or some other appropriate surface. In
particular, the illustrated gliding devices 1 are designed as sports
devices for practicing different types of winter sports, such as alpine
skiing, cross-country skiing or snowboarding.

[0024] FIG. 1 illustrates one possible embodiment of a ski 2, whereas the
embodiment illustrated in FIG. 3 represents one possible design of a
snowboard 3. The ski 2 may also be what is known as a cross-country ski.
Schematically indicated by broken lines on these gliding devices 1 is a
generally standard binding unit 4 for releasably connecting the gliding
device 1 to a user's shoe or foot as and when necessary.

[0025] In a manner known per se, a gliding device 1 of this type is formed
by a multi-layered sandwich element 5, made up of individual layers 6, 7,
8 joined to one another non-positively and/or positively, in particular
bonded, and a layer or ply more or less at the centre has the biggest
cross-sectional dimension compared with the outer layers and thus forms
the so-called core 9 of the sandwich element 5. The core 9 may be made
from wood, in particular several bonded plies joined to one another to
form an integral component, preferably made from hardwood. It is also
possible for the core 9 of the gliding device 1 to be made from a foamed
plastic and/or profiled elements of lightweight metal, carbon or such
like.

[0026] Layers 6 and/or 7 and/or 8 disposed in the outer peripheral region
of the cross-section of the gliding device 1 therefore constitute the
so-called top and/or bottom belt of the sandwich element 5 or gliding
device 1. These layers 6, 7, 8 are made from materials with a relatively
high tensile strength and may be selected from the group comprising
metals, such as aluminum, titanium, resin-impregnated woven fabrics,
plastics, and are crucial in terms of defining the mechanical properties
of the gliding device 1, in particular the bending stiffness and/or
breaking strength. In this respect, it would be possible to use any
combination of different materials for the individual layers 6, 7, 8.

[0027] The outermost layer 6 in the embodiment illustrated as an example
is a top layer 10 of the gliding device 1. This uppermost top layer 10 is
preferably made from plastic and primarily fulfils a decorative and
protective function for the gliding device 1. Alternatively, however, the
top layer 10 might also be made from metal, in particular lightweight
metal such as aluminum, titanium or similar for example. The top layer 10
preferably extends in a cap-type arrangement from a first longitudinal
side region 11 across a top face 12 of the gliding device 1 to the other
longitudinal side region 13 of the gliding device 1. Instead of opting
for the design based on a cap-type top layer 10, however, it would also
be possible for the top layer 10 to extend within the region of the top
plane of the gliding device 1 only, in which case the so-called side
edges of the gliding device 1 are provided as separate components,
preferably of plastic.

[0028] Disposed on a bottom face 14 of the gliding device 1 facing away
from the top face 12 is a running surface layer 15, intended for gliding
over the ground underneath, such as ice or snow, for example. The running
surface layer 15 is usually made from a plastic with as low a frictional
resistance to snow or ice as possible and a sufficient resistance to
scratching. The peripheral regions of the running surface layer 15 or
gliding device 1 are usually bounded by sharp-edged elements 16, 17 with
a relatively high hardness, for example made from steel. These
sharp-edged elements 16, 17 thus form steel edges for guiding the gliding
device 1 exactly and without slipping on ice or snow.

[0029] It is also of advantage if at least one external face 18 of the top
layer 10 facing away from the core 9 has an at least partially structured
surface 19. This three-dimensionally structured surface 19 may be formed
by a plurality of holes 20 or perforations

[0030] As may best be seen from FIG. 2, the holes 20 are disposed in and
extend through the outermost top layer 10 of the gliding device 1
exclusively. In this respect, a depth 21 of the holes 20 corresponds
respectively to a maximum thickness 22 or depth of the top layer 10. Thin
lacquer or decorative films and/or thin-layered films which reduce the
adhesion of ice or snow may also be provided on this top layer 10,
although these are not specifically illustrated.

[0031] The purpose of the holes 20 is to improve grip when carrying the
gliding devices and thus reduce or totally prevent any unintentional
slipping when the gliding devices are being carried by the top layer 10.
This being the case, depending on the cross-section of the holes 20,
either the human skin or alternatively a glove if one is being worn is
able to penetrate at least certain regions, thereby imparting better grip
to the usually smooth surface, thereby facilitating handling of the
gliding devices 1. The layer 6 constituting the top layer 10 is usually a
relatively thin layer or a film. To provide a clearer illustration,
however, the thickness 22 is illustrated on a disproportionately large
scale.

[0032] It has proved to be of practical advantage to provide holes 20
which, when seen in plan view as illustrated in FIG. 1 or 3, have a
surface dimension or cross-section within a lower limit of approximately
0.5 mm2, preferably 1 mm2, and an upper limit of 8 mm2,
preferably 3 mm2. The surface density, i.e. the number of holes 20
per surface unit, may easily be varied depending on the intended use and
cross-sectional size. The area where they are applied in the top layer 10
may also be different from that illustrated in the two examples. This
offers a way of significantly influencing the intended, attractive
overall appearance or visual effect of the gliding device 1. In
particular, the holes 20 as such may no longer be perceptible when viewed
from a greater distance if they are of a very small design, although they
will not then be as practical. The grip on the gliding devices 1 is also
reduced at the intended points.

[0033] A structured top layer 10 of this type with differing patterns of
holes 20 specifically imparts an attractive appearance to the gliding
device 1. Irrespective of this, however, it would also be possible to
make lettering by arranging the holes 20 accordingly and by using a
material for the layer 7 disposed underneath or below of a different
color from the material of the top layer 10.

[0034] The outermost layer 6 constituting the top layer 10 is shown with
an over-exaggerated thickness 22, and the thickness 22 usually varies
within the film thickness range of between 0.5 mm and 2.0 mm. In order to
join the layer 6 serving as the top layer 10 to the other layer 7
disposed underneath it, an adhesive layer 23 indicated by a thicker line
is provided. This adhesive layer 23 is preferably an adhesive which is
activated by heat. Such adhesives are also referred to in the industry as
so-called "hot melt" adhesives. The adhesive may also be activated by
applying pressure and this may be combined with the process of applying
heat mentioned above.

[0035] FIG. 4 illustrates a detail on a larger scale of the mutually
joined layers 6, 7 and the adhesive layer 23 joining them and the core 9.
As may be seen from the enlarged, schematic diagram, the adhesive layer
23 is interrupted in the region of the holes 20. This prevents excessive
adhesive from being able to get into the hole or holes 20 during the
process of bonding to the layer 7 disposed underneath and at least
partially filling them, whilst on the other hand offering a way of
providing an unobstructed or non-clouded view through the hole or holes
20 to the layer 7 disposed underneath. Precisely in the case of
thin-walled top layers 10, a situation can quite easily occur in which
the hole or holes 20 become at least partially filled. It is of advantage
to provide a free view through the hole or holes 20 to the surface of the
other layer 7 joined to it by the adhesive layer 23 if the layer 7 is
made from a material of a different color from that of the top layer 10,
since this enables an additional visual effect to be achieved. The holes
20 could then be used to depict a company logo, lettering or similar, for
example.

[0036] In this respect, the procedure adopted is to apply the adhesive
layer 23 to an internal face 24 of the layer 6 forming the top layer 10
facing away from the external face 18 and designed to be bonded to the
layer 7 disposed underneath, at least in the region where the hole 20 is
to be made. The adhesive layer 23 is preferably applied to the full
surface of the entire internal face 24. A variety of methods may be used
for this purpose. For example, a spraying process, lamination with an
adhesive film or alternatively a simple coating process would be
conceivable. If the heat-activatable adhesive layer 23 is to be joined to
the layer 6, the holes 20 are made jointly both through the layer 6 and
through the adhesive layer 23. This may be done by a punching and/or
cutting process, for example, in which case both the material of the top
layer 10 as well as that of the adhesive layer 23 is removed from the
region of the hole holes 20 together in a single work step. Depending on
the chosen pattern and layout of the holes 20 with respect to one
another, a perforated layer 6 and top layer 10 are formed which, on their
surface intended for bonding, namely the internal face 24, are provided
with the adhesive layer 23 likewise incorporating holes 20.

[0037] In order to join the layer 6 and top layer 10 prepared in this
manner and incorporating at least one but preferably several holes 20 to
the layer 7 disposed underneath, they may optionally be cut to size
and/or made ready to suit the gliding device 1 to be produced prior to
the bonding process, after which the bonding operation may be carried out
in a press or similar, for example.

[0038] For the joining process, the layer 6 constituting the top layer 10
is heated in a manner known per se to the degree that the adhesive layer
23 disposed on the internal face 24 remote from the external face 18 also
melts and forms a stable and strong connection to the layer 7 after the
cooling process. Due to the fact that the adhesive layer 23 is also
interrupted in the region of the hole or holes 20, the layer 6 is bonded
exclusively in only the regions disposed between the holes 20 and in the
region or portion surrounding the hole 20. In this respect, a plurality
of preferably different holes 20 may be distributed or disposed across
the entire surface of the top layer 10, in which case the adhesive layer
23 is disposed around the holes 20 and between them.

[0039] During this joining process in the past, the two layers 6, have
usually been bonded by means of a film-type adhesive layer which can be
activated by heat but which is disposed across the entire surface. During
the joining process, when the adhesive layer was activated accordingly,
adhesive in the region of the hole 20 was also melted and was able to
penetrate the hole 20, thereby at least partially closing it. The
disadvantage of this is that not only is the grip lost in the region of
the top layer 10, which is usually very thin, the visual appearance is
also detrimentally affected or even lost altogether.

[0040] The embodiments illustrated as examples represent possible variants
of the design and disposition of the top layer 10, and it should be
pointed out at this stage that the invention is not specifically limited
to the variants specifically illustrated, and instead the individual
variants may be used in different combinations with one another and these
possible variations lie within the reach of the person skilled in this
technical field given the disclosed technical teaching. Accordingly, all
conceivable variants which can be obtained by combining individual
details of the variants described and illustrated are possible and fall
within the scope of the invention.

[0041] For the sake of good order, finally, it should be pointed out that,
in order to provide a clearer understanding of the structure of the top
layer 10 and the gliding device 1 incorporating it, they and their
constituent parts are illustrated to a certain extent out of scale and/or
on an enlarged scale and/or on a reduced scale.

[0042] The objective underlying the independent inventive solutions may be
found in the description.

Patent applications by Georg Klausner, St. Johann AT

Patent applications by Helmut Holzer, St. Johann AT

Patent applications in class Subsequent to assembly of laminae

Patent applications in all subclasses Subsequent to assembly of laminae